Method of Making An Automotive Trim Part With Applique

ABSTRACT

The present invention provides for an improved trim part, e.g. a bolster or trim plate, with integrated appliqué for use in a trim assembly, and to a continuous two-shot molding operation that may be performed utilizing a single mold assembly. In an exemplary embodiment, the trim part, i.e. a bolster, includes a substrate formed by injecting a first material into a first shot mold cavity in a first shot of a molding operation. An appliqué is provided in a second shot mold cavity then a cover is formed between the substrate and appliqué by injecting into a mold chamber a second foamed material in a second shot of the molding operation. The formed cover is integrally molded to at least a portion of the substrate and the appliqué to form a trim part with integrated appliqué.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of pending U.S. patent application Ser. No. 10/904,007 (pending), filed Oct. 19, 2004, the disclosure of which is hereby incorporated by reference herein. This application is also related to U.S. Ser. No. 10/708,312, filed Feb. 24, 2004, U.S. Ser. No. 10/904,008, filed Oct. 19, 2004, U.S. Ser. No. 10/904,010, filed Oct. 19, 2004, U.S. Ser. No. 10/904,011, filed Oct. 19, 2004, U.S. Ser. No. 10/904,032, filed Oct. 20, 2004, U.S. Ser. No. 10/711,692, filed Sep. 30, 2004, U.S. Ser. No. 10/904,033, filed Oct. 20, 2004, U.S. Ser. No. 10/904,433, filed Nov. 10, 2004, U.S. Ser. No. 10/904,409, filed Nov. 9, 2004, U.S. Ser. No. 10/904,408, filed Nov. 9, 2004 and U.S. Ser. No. 10/904,407, filed Nov. 9, 2004.

FIELD OF THE INVENTION

The present invention pertains to a method of making trim assemblies for automotive interiors and, more particularly, to an automotive trim part having an integrated appliqué such as for use in a trim assembly.

BACKGROUND OF THE INVENTION

It is known to provide automotive interiors with various trim parts to enhance the aesthetic appearance of the automotive interior, and to provide comfort to vehicle occupants. Examples of some of these interior trim parts include instrument trim panels, door trim panels, console panels, armrests, bolsters, handles, trim plates, and airbag covers. To increase the aesthetic appearance of these trim parts and to improve the comfort to vehicle occupants, it is desired to provide at least portions of the trim parts, such as bolsters, with appliqués or decorative areas.

One primary drawback with current trim parts having decorative areas is in the manufacturing and assembly thereof. These trim parts, such as bolsters, typically, have been formed by insertion of a resilient padding material beneath a pliable surface or skin layer of decorative trim material, such as a textile or fabric like woven cloth, vinyl, and/or leather. The preformed resilient pad also may be secured to a rigid plastic shell and a pliable skin layer stretched over the pad and secured to the shell to form the decorative trim part. In other cases, padding is omitted to provide a rigid base and a decorative trim material that is adhesively bonded thereto. In another conventional method of forming trim parts with decorative areas for use in trim assemblies, a foam material may be injected between a rigid substrate and a decorative skin layer, already joined to the substrate. Consequently, the above noted methods are generally costly due to the multiple components and manufacturing steps required to make these decorative trim parts.

There is thus a need for an improved trim part with integrated appliqué for use in a trim assembly, and a method for making the same, that reduces the number of parts and the labor required for assembly thereof thereby reducing overall manufacturing costs.

SUMMARY OF THE INVENTION

The present invention provides for an improved trim part, such as a bolster, with an integrated appliqué for use in a trim assembly, e.g. a door trim panel assembly. It should be understood that the trim part may include any desired automotive trim part such as an instrument trim panel, door trim panel, console panel, armrest, handle, trim plate, airbag cover, etc, for use in any desired trim panel assembly, such as a door trim panel assembly, instrument panel assembly, console assembly, etc.

To this end, the trim part is an integrated, unitary structure that includes a substrate made from a first material, which may include a thermoplastic polymer such as a thermoplastic olefin, e.g. polypropylene, or polycarbonate/acrylonitrile butadiene styrene. A cover is integrally molded to at least a portion of the substrate and is composed of a second foamed material. The second foamed material may be a foamed thermoplastic polymer including a foamed thermoplastic elastomer or foamed polypropylene such as to provide a soft-feel. The foamed material generally produces a lightweight cover that includes an outer skin and a cellular inner core such that the outer skin deforms and compresses the inner core when a force is applied thereby providing a soft feel to the trim part. The second foamed material is activated, or foamed, by a blowing agent, such as sodium bicarbonate, nitrogen, or any other commonly known blowing agent.

An appliqué, or decorative cut-out, is provided, i.e. integrated, within a portion of the cover such that the cover is integrally molded to at least a portion of the appliqué to retain the appliqué. The appliqué creates a more aesthetically pleasing trim part, and includes a decorative material such as a textile or fabric like material including a woven cloth, vinyl, and/or leather, a plastic material, a metal piece, and the like. The appliqué further may be provided with a symbol(s) such as a letter(s), number(s), word(s), logo(s), picture(s), and the like.

The automotive trim part, e.g. a bolster, with integrated appliqué is formed in a continuous two-shot molding process. In this operation, a mold assembly is provided in which the substrate is formed by injecting the first material into a first shot mold cavity in a first shot of the molding operation. A core of the mold assembly is used, advantageously rotated, to move the substrate from the first shot mold cavity to a second shot mold cavity. The appliqué is provided within a portion of the second shot mold cavity then a mold chamber is formed about at least a portion of the substrate and the appliqué within the second shot mold cavity.

The cover then is integrally molded intermediate the substrate and appliqué by injecting into the mold chamber the second foamed material in a second shot of the molding operation, the cover being molded to at least a portion of the substrate and the appliqué to form the trim part with integrated appliqué. In addition, the foamed second material advantageously generally provides the trim part with a soft feel. In an exemplary method, the mold assembly for forming the trim part with appliqué includes first and second shot mold cavities and a rotatable core having first and second male portions adapted to mate with each cavity for forming a plurality thereof in a continuous manner.

By virtue of the foregoing, there is thus provided an improved trim part, such as a bolster, with an integrated appliqué, and a method of making the same, that reduces the number of parts and the labor required for assembly thereof thereby reducing overall manufacturing costs.

The features and objectives of the present invention will become more readily apparent from the following Detailed Description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the invention.

FIG. 1 is a perspective view of an automotive interior trim assembly including a trim part with appliqué according to the present invention;

FIG. 1A is a cross-sectional view of FIG. 1 taken along the lines 1A-1A;

FIG. 1B is a perspective view with a partial cut-away section of an another embodiment of the automotive interior trim part with appliqué according to the present invention;

FIG. 2 is a perspective view of a mold assembly used to form the trim part with appliqué of FIG. 1;

FIG. 2A is a cross-sectional view of the mold of FIG. 2 taken along the line 2A-2A illustrating the first shot of the molding operation of the trim part;

FIG. 3 is a perspective view of the mold assembly of FIG. 2 depicting the rotational movement from the first shot mold cavity to the second shot mold cavity of the formed substrate of FIG. 2A; and

FIG. 3A is a cross-sectional view of the mold of FIG. 3 taken along the line 3A-3A illustrating the second shot of the molding operation of the trim part.

DETAILED DESCRIPTION OF THE DRAWINGS

In FIG. 1, an automotive interior trim assembly, i.e. a door trim panel assembly 8, for an automobile (not shown) includes an exemplary embodiment of the trim part, i.e. a bolster 12, with integrated appliqué 14. It should be understood that the trim part 12 with integrated appliqué 14 can include any desired automotive trim part, such as an instrument trim panel, door trim panel, console panel, armrest, handle, trim plate, airbag cover, etc., with each generally being constructed in a similar fashion. Thus, while the following detailed description focuses primarily on the bolster 12 with integrated appliqué 14, those having ordinary skill in the art will recognize that other trim parts having integrated appliqués may equally be considered for use in any desired trim assembly.

With continuing reference to FIG. 1, a door trim panel 10 of the trim panel assembly 8 covers a portion of the interior of the automobile (not shown) and includes the bolster 12 with integrated appliqué 14 to provide a more aesthetically pleasing environment. The door panel 10 further includes an armrest 15 with a handle portion 16 configured for grasping by a vehicle occupant to facilitate, for example, closing of a car door 18. A variety of openings, additionally, can be included in the trim panel 10 so as to accommodate the placement of hardware components 20 such as a speaker(s), door handle, window controls, etc.

As best shown in FIGS. 1 and 1A, the bolster 12 defines an integrated, unitary structure and includes a substrate 24 made from a first material 26. The first material 26 may include a thermoplastic polymer such as a thermoplastic olefin, e.g. polypropylene, or polycarbonate/acrylonitrile butadiene styrene. Notably, the thickness of the substrate advantageously is about 1-5 mm, more advantageously about 2-4 mm, most advantageously about 3 mm.

A cover 28 is integrally molded to at least a portion of the substrate 24 and is made from a second foamed material 30. It should be understood that the cover 28 may be provided over the entire substrate 24 or any portion thereof. The second foamed material 30 may be a foamed thermoplastic polymer including a foamed thermoplastic elastomer or foamed polypropylene such as to provide a soft-feel. The second foamed material 30 may be activated, or foamed, by a blowing agent, such as sodium bicarbonate and the like, any gas such as nitrogen, or any other commonly known blowing agent. More specifically, the blowing agent is combined, or mixed, with a thermoplastic polymer, such as a thermoplastic elastomer or polypropylene, advantageously a thermoplastic elastomer available from Kraiburg TPE, Corp. of Duluth, Ga., to produce the second foamed material 30. The blowing agent advantageously is present in an amount from 0.1% to 5% by weight of the mixture, more advantageously from 0.5% to 3% by weight.

The foamed material 30 produces the cover 28 which includes an outer skin 34 and a cellular inner core 36 such that the outer skin 34 deforms and compresses the inner core 36 when a force is applied thereby advantageously providing a soft feel to the trim part 12. Notably, the feel of the cover 28 may be varied, or adjusted, to any desired softness by changing the thickness thereof. At a thickness of about 1.5 mm or less, the cover 28 defines an outer skin 34 but is substantially devoid of a soft inner core 36 because of an inability of the core 36 to be foamed. As such, the thickness of the cover 28 advantageously is about 5-12 mm, more advantageously about 7-9 mm, and most advantageously about 8 mm.

An appliqué 14, or cut-out decoration, is provided, i.e. integrated, within a portion of the cover 28 such that the cover 28 is integrally molded to at least a portion of the appliqué 14 to retain the appliqué 14. The appliqué 14 includes a decorative material such as a textile or fabric like material including a woven cloth, vinyl, and/or leather, a plastic material, a metal piece, and the like, and creates a more aesthetically pleasing trim part 12 for the vehicle driver or occupant. The appliqué 14 further may be provided with a symbol(s) 38 (See FIG. 1B) such as a letter(s), number(s), word(s), logo(s), picture(s), and the like. The appliqué 14, as shown in FIG. 1, includes a woven cloth material.

Referring further to FIGS. 1 and 1A, the bolster 12 with integrated appliqué 14 is formed separately from the door trim panel 10 and secured thereto by means (not shown) commonly known in the art, such as by an adhesive, screws, clips, tacks, male portions, and the like. As such, the bolster 12 can be permanently secured or removably attached to the door trim panel 10 and may cover an access opening (not shown) defined therein such that when the bolster 12 is removed, a technician or assembly line worker can access the space behind the trim panel 10 to install or service door components and their drive mechanisms. In other cases, the trim part, i.e. the bolster 12, may be integrally molded to the door trim panel 10 and, more specifically, the substrate 24 and/or cover 28 of the bolster may be integrated, i.e. integrally molded, within the door panel 10 to provide an integrated bolster 12 with integrated appliqué 14.

In another embodiment, as best shown in FIG. 1B, the trim part 12 generally may be a trim plate 12 a with integrated appliqué 14. Accordingly, the trim plate 12 a with integrated appliqué 14 similarly defines an integrated, unitary structure and includes the substrate 24 made from the first material 26, the integrally molded cover 28 made from the second foamed material 30, and the integrated appliqué 14, which is shown including a metal piece provided with a symbol 38 thereon. The trim plate 12 a further is shown as having been formed separately by the methods further described below, and can be attached by means commonly known in the art, such as by an adhesive, to any desired trim part such as a bolster, armrest, airbag cover, door panel, console panel, etc., to provide a decorative look.

With reference to FIGS. 2-3A, a method of making the automotive trim part, i.e. the bolster 12, with appliqué 14 of the present invention will now be described. As best shown in FIG. 2, a single mold assembly 42 includes spaced apart first and second shot mold cavities 44 and 46 and a central core 48 having first and second male portions 50 and 52 adapted to mate with each cavity 44, 46. The core is 48 situated between the mold cavities 44, 46 and is adapted to rotate about a central axis, i.e. a horizontal axis 56, so that the first and second male portions 50, 52 can mate, in turn, with the mold cavities 44, 46 to mold, in sequence, first the substrate 24 then the cover 28 with integrated appliqué 14 in a continuous manner.

It should be understood by the artisan that variations of the mold assembly 42 may be provided and still fall within the scope of this invention. For example, any number of core male portions 50, 52 (i.e. more or less than shown) may be provided, in conjunction with the necessary number of corresponding first and second shot mold cavities 44, 46, for molding the trim part 12 with integrated appliqué 14.

While the first and second shots of the molding operation are further described below with respect to the first male portion 50 by utilizing the cross-sectional views of FIGS. 2 and 3, it is understood that the first and second shot molding process occurs in the same fashion with respect to the second male portion 52. Accordingly, as best shown in FIGS. 2 and 2A, the first male portion 50 of the core 48 mates with the first shot mold cavity 44 and, more specifically, the first shot mold cavity 44 is adapted to move toward the first male portion 50, as is commonly known in the art, to form a first shot chamber 60.

In a first shot of the molding operation, the first material 26, which may be a thermoplastic polymer such as a thermoplastic olefin, e.g. polypropylene, or polycarbonate/acrylonitrile butadiene styrene, is injected through a channel 62 into the chamber 60 to form the substrate 24 of the bolster 12. Specifically, the substrate 24 is molded over the first male portion 50 such that the first male portion 50 retains the molded substrate 24. Notably, the thickness of the substrate advantageously is about 1-5 mm, more advantageously about 2-4 mm, most advantageously about 3 mm.

With further reference to FIGS. 3 and 3A, the first shot mold cavity 44 is retracted, or moved away from, the first male portion 50, and the core 48 having the first male portion 50 provided with the substrate 24 then is rotated about the horizontal axis 56 to move the substrate 24 from the first shot mold cavity 44 to the second shot mold cavity 46. It should be understood that the core 48 also may rotate about a vertical axis or be adapted to move, or slide, sideways to the second shot mold cavity 46.

The second shot mold cavity 46 includes a placement area 63 (FIG. 2) adapted to receive and retain the appliqué 14 in anticipation of a second shot of the molding operation wherein the cover 28 for the trim part 12 is molded. Notably, the placement area 63 includes a recess that is defined by four walls 64 (FIG. 2) and further is configured to receive the appliqué 14. The walls 64 of the placement area 63 help retain the appliqué 14 therein. For certain appliqués 14, such as certain textile or fabric like materials including woven cloth, that lack the structural support to be retained within the placement area 63, one or more vacuum holes 65 can be provided therein. Accordingly, the vacuum holes 65 are connected to a vacuum (not shown), as is known in the art, for holding the appliqué 14 in place for the second shot of the molding operation.

The depth of the placement area 63 may be adjusted according to the thickness of the appliqué 14 and/or according to the desired depth of integration within the cover 28. In view thereof, the placement area 63 may be defined by an even, or a raised, surface (not shown). In addition, the placement area 63 may be defined by nibs (not shown), or ribs (not shown), configured and adapted to receive and retain the appliqué 14. It is further understood that various combinations of the aforementioned may be utilized for receiving and retaining the appliqué 14.

Accordingly, with further reference to FIGS. 3 and 3A, the appliqué 14 is placed within the placement area 63 (FIG. 2) by means (not shown) commonly known in the art, e.g. manually or robotically. Next, the first male portion 50 of the core 48 mates with the second shot mold cavity 46 and, more specifically, the second shot mold cavity 46 is adapted to move toward the first male portion 50, as is commonly known in the art, to form a second shot chamber 66 about at least a portion of the substrate 24 and the appliqué 14.

In the second shot of the molding operation, the second foamed material 30, which may be a foamed thermoplastic polymer such as a foamed thermoplastic elastomer or foamed polypropylene, is injected through a channel 70 into the second shot chamber 66 to form the cover 28. As best shown in FIG. 3A, the cover 28 is molded intermediate the substrate 24 and appliqué 14 so that the cover 28 integrally molds to at least the portion of the substrate 24 and the appliqué 14 to form the trim part 12 with integrated appliqué 14. As indicated above, the second foamed material 30 is activated, or foamed, by a blowing agent that can include sodium bicarbonate and the like, any gas such as nitrogen, or any other known blowing agent. More specifically, the blowing agent is combined, or pre-mixed, with a thermoplastic polymer, such as a thermoplastic elastomer or polypropylene, to form the second foamed material 30.

The foamed material 30 produces the cover 28, which advantageously includes an outer skin 34 and a cellular inner core 36 such that the outer skin 34 will deform and compress the inner core 36 when a force is applied thereby providing a soft feel. The feel of the cover 14 may be varied, or adjusted, to any desired softness by changing the thickness thereof, such as by altering the depth of the second shot chamber 66. At a thickness of about 1.5 mm and less, the cover defines an outer skin 34 but is substantially devoid of a soft inner core 36 because of an inability of the core 36 to be foamed. As such, the thickness of the cover advantageously is about 5-12 mm, more advantageously about 7-9 mm, and most advantageously about 8 mm.

After the second foamed material 30 has been allowed time sufficient to cure, the second shot mold cavity 46 is retracted, or moved away from, the first male portion 50, and the trim part, i.e. bolster 12, with integrated appliqué 14 is ejected from the first male portion 50, such as by ejector pins (not shown), so that the process may begin anew.

Although not illustrated, it is understood that the second male portion 52 also is adapted to mate with the first shot cavity 44, during the mating of the first male portion 50 with the second shot mold cavity 46, to form a second substrate (not shown) that may be identical to the first substrate 24 by injecting the first material 26 into the first shot mold cavity 44 in the first shot of the molding operation. After injection, the core 48 with the second male portion 52 similarly rotates the second substrate to the second shot mold cavity 46 for the second shot of the molding operation while the first male portion 50 returns to the first shot mold cavity 44 to repeat the first shot of the molding operation. In this fashion, a plurality of automotive trim parts 12 with integrated appliqué 10 may be formed in a continuous and efficient manner.

With further reference to FIGS. 1 and 3A, the molded bolster 12 includes the substrate 24, the cover 28 integrally molded thereto, and the appliqué 14 integrated within the cover 28, i.e. the cover 28 integrally molded to the appliqué 14. The bolster 12 with integrated appliqué 14 now may be coupled, by means known in the art, to the door trim panel 10 for use in a trim assembly 8. Accordingly, the molding operation of the present invention may be continuously performed utilizing a single mold assembly 42 to provide an improved trim part, i.e. a bolster 12, with integrated appliqué 14.

Although, the method of making utilizes a single mold assembly 42 for a continuous, integrated process, it still should be understood that the molding process may be performed in more than one mold assembly such that the substrate 24 may be moved from the first shot mold cavity 44 after the first shot to a second shot mold cavity 46 provided in a second, separate mold assembly (not shown) for the second shot of the molding operation. Movement can be manually or by other means commonly known in the art, e.g. robotically.

While the present invention has been illustrated by the description of the various embodiments thereof, and while the embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope or spirit of Applicant's general inventive concept. 

1. A method of forming an automotive trim part with an integrated appliqué in a two-shot molding operation, comprising: molding a substrate by injecting a first material in a first shot of the molding operation; providing an appliqué; forming a mold chamber about at least a portion of the substrate and the appliqué; and molding a cover intermediate the portion of the substrate and the appliqué by injecting into the mold chamber a second foamed material in a second shot of the molding operation, the cover being molded to at least the portion of the substrate and the appliqué to form the trim part with an integrated appliqué.
 2. The method of claim 1, wherein the step of molding a substrate by injecting a first material includes molding the substrate by injecting a thermoplastic polymer; and wherein the step of molding a cover by injecting a second foamed material includes molding the cover by injecting a foamed thermoplastic polymer.
 3. The method of claim 1, wherein the step of molding a substrate by injecting a first material includes molding the substrate by injecting a thermoplastic polymer; and wherein the step of molding a cover by injecting a second foamed material includes molding the cover by injecting one of a foamed thermoplastic elastomer and foamed polypropylene.
 4. The method of claim 1, wherein the step of providing an appliqué comprises providing the appliqué including a decorative material.
 5. The method of claim 1, wherein the step of providing an appliqué comprises providing the appliqué having a symbol thereon.
 6. The method of claim 1, wherein the formed trim part with an integrated appliqué is one of a trim plate and a bolster with an integrated appliqué.
 7. A method of forming an automotive trim part with an integrated appliqué in a continuous two-shot molding operation, comprising: providing a mold assembly having first and second shot mold cavities; molding a substrate by injecting a first material into the first shot mold cavity of the mold assembly in a first shot of the molding operation; providing the second shot mold cavity with an appliqué; moving the substrate from the first shot mold cavity to the second shot mold cavity by using at least a portion of the mold assembly; forming a mold chamber about at least a portion of the substrate and the appliqué within the second shot mold cavity of the mold assembly; and molding a cover intermediate the portion of the substrate and the appliqué by injecting into the mold chamber a second foamed material in a second shot of the molding operation, the cover being molded to at least the portion of the substrate and the appliqué to form the trim part with an integrated appliqué.
 8. The method of claim 7, wherein the step of molding a substrate by injecting a first material includes molding the substrate by injecting a thermoplastic polymer; and wherein the step of molding a cover by injecting a second foamed material includes molding the cover by injecting a foamed thermoplastic polymer.
 9. The method of claim 7, wherein the step of molding a substrate by injecting a first material includes molding the substrate by injecting a thermoplastic polymer; and wherein the step of molding a cover by injecting a second foamed material includes molding the cover by injecting a foamed thermoplastic elastomer or foamed polypropylene.
 10. The method of claim 7, wherein the step of providing an appliqué comprises providing the appliqué including a decorative material.
 11. The method of claim 7, wherein the step of providing an appliqué comprises providing the appliqué having a symbol thereon.
 12. The method of claim 7, wherein the formed trim part with an integrated appliqué is one of a trim plate and a bolster with an integrated appliqué.
 13. The method of claim 7, wherein the step of providing a mold assembly having first and second shot mold cavities comprises providing a mold assembly having first and second shot mold cavities and a core having at least one male portion adapted to mate with each cavity, the core further being adapted to rotate; wherein the step of molding a substrate comprises molding the substrate by mating the at least one male portion with the first shot mold cavity and injecting the first material into the first shot mold cavity in the first shot of the molding operation; wherein the step of moving the substrate comprises rotating the substrate on the at least one male portion of the core from the first mold cavity to the second mold cavity; and wherein the step of forming a mold chamber comprises forming the mold chamber about at least a portion of the substrate and the appliqué within the second shot mold cavity of the mold assembly by mating the at least one male portion with the second shot mold cavity to mold the cover therebetween in the second shot of the molding operation.
 14. The method of claim 13, wherein the step of rotating the substrate comprises rotating the substrate about a horizontal axis to move the substrate from the first shot mold cavity to the second shot mold cavity. 